Extrusion International 5-2026

31 Extrusion International 5/2026 AI in Extrusion Manufacturing – Hype, Tool, or the Next Industrial Revolution? By: Dariusz Kozlowski Arti cial Intelligence has become one of the most discussed technologies in manufacturing, but separating genuine industrial value from marketing hype is not always easy. In the extrusion sector, however, AI is beginning to move beyond theory and pilot projects into practical applications that can deliver measurable bene ts. E xtrusion processes generate vast amounts of data every second. Temperatures, pressures, screw load, drive power, line speed, cooling performance, material feed rates, dimensional measurements, and quality in- spection data are all continuously recorded by modern control systems. Historically, much of this information has been used only for monitoring and troubleshoot- ing. AI offers the ability to turn that data into actionable process intelligence. Unlike conventional automation systems that operate using prede ned rules and control loops, AI systems can uncover relationships between variables that may not be obvious, even to experienced process engineers. As a result, AI has the potential to improve process stability, reduce waste, lower energy consumption, and support more consistent product quality. The long-term signi cance of this technology may ul - timately be comparable to the industry's transition from analogue controls to PLC-based automation during the 1980s and 1990s. Why Extrusion Is Well Suited to AI Extrusion is inherently a multivariable process. A change in one operating parameter often inuences numerous other process conditions. For example, a variation in raw material characteris- tics may affect melt viscosity. This can inuence die pres - sure, motor load, dimensional control, cooling ef cien - cy, and ultimately nished product quality. Experienced operators learn these interactions over many years of production experience, but monitoring them simultane- ously is challenging. EXTRUSION TECHNOLGIES, AI Engineered to perform. Cast MDO technology for excellent film properties. www.sml.at • Wide application range and exibility in lm production • Good atness for printing applications • Safe and easy-to-service design Dariusz Kozlowski talking to customers